This handy jig–which is basically an oversized miter gauge with a large fence and double runners for better workpiece bearing and stability–lets you crosscut large workpieces with accuracy and ease. Its advantage over a traditional crosscut sled is the ability to make a full-depth cut, as there’s no bottom sled panel raising the workpiece. The plywood base keeps the fence dead-straight and serves as a solid connection for the runners while allowing adjustment if necessary to square up the fence. The tapered ends of the fence allow better hand access for holding down narrow work.
Use quartersawn hard maple or other straight-grained hardwood for the fence, and 3⁄4"-thick hardwood plywood for the base, stacking pieces at the center to serve as a blade cover. Drill the attachment holes through the steel bar stock (available at www.mcmaster.com and other metal suppliers) with a #7 bit before cutting the threads with a 1⁄4-20 tap. Trim the leading edge of the base flush and square, and then glue the fence to it.
With the runners in their slots, measure the precise distances between the hole center points, and transfer those locations onto the base. Drill 5⁄16"-diameter holes at those points, also counterboring to recess for 1⁄4-20 × 1" hex-head cap screws and washers. Loosely attach the runners with the cap screws and washers, square the fence to the fully raised blade, and then tighten the screws. Make a test cut, and readjust if necessary. When correct, you’ll get perfectly square crosscuts every time.
—Andy Rae, Asheville, North Carolina
